INCORPORATION BY REFERENCE

[0001] The entirety of U.S. Provisional Application Serial No. 61/592,227, filed on January 30, 2012, is hereby expressly incorporated herein by reference.

BACKGROUND

1. Field of the Inventive Concepts

[0002] The inventive concepts disclosed herein relate generally to materials lifting apparatuses, and more particularly, but not by way of limitation, to a pipe conveyor apparatus for transporting pipe between a pipe storage rack and a rig floor which is elevated above the pipe storage rack.

2. Brief Description of Related Art

[0003] In the drilling and servicing of a well, tubular members such as drill pipe, casing, and production tubing must be transported between a pipe storage rack and a rig floor. For instance, it is necessary periodically to pull the drill string out of the well bore ("tripping out") to replace the drill bit and in turn run the drill string back into the well bore. This process involves a series of repetitive steps in which joints of pipe are withdrawn from the well bore, disconnected, and stored on the pipe storage rack. The process is then repeated in reverse order to replace the drill string in the well bore. Due to the fact that the rig floor can be as much as 20 to 30 feet above ground level, numerous devices have been previously proposed to assist in the movement of the tubular members between the pipe storage rack and the rig floor. Such devices are generally complex in construction, can result in damage to the pipe, particularly the pipe threads, and are not easily transported from one rig to another.

[0004] To this end, a need exists for an improved pipe conveyor apparatus which is simple in construction, easy to transport and operate, and which reduces damage to tubular members. It is to such an apparatus that the inventive concepts disclosed herein are directed

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a perspective view of a pipe conveyor apparatus constructed in accordance with the inventive concepts disclosed herein shown in use transporting pipe between a set of pipe racks and a floor of a rig. [0006] FIG. 2 is a perspective view of the pipe conveyor apparatus.

[0007] FIG. 3 is a front elevational view of the pipe conveyor apparatus.

[0008] FIG. 4 is an enlarged, perspective view of a portion of the pipe conveyor apparatus.

[0009] FIG. 5 is an enlarged, perspective view of a distal end of a boom of the pipe conveyor apparatus.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0010] Before explaining at least one embodiment of the inventive concepts disclosed herein in detail, it is to be understood that the inventive concepts are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. The inventive concepts disclosed herein are capable of other embodiments, or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting the inventive concepts disclosed and claimed herein in any way.

[0011] In the following detailed description of embodiments of the inventive concepts, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concepts. However, it will be apparent to one of ordinary skill in the art that the inventive concepts within the instant disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the instant disclosure.

[0012] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," and any variations thereof, are intended to cover a nonexclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements, and may include other elements not expressly listed or inherently present therein.

[0013] Unless expressly stated to the contrary, "or" refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0014] In addition, use of the "a" or "an" are employed to describe elements and components of the embodiments disclosed herein. This is done merely for convenience and to give a general sense of the inventive concepts. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

[0015] As used herein, qualifiers like "substantially," "about," "approximately," and combinations and variations thereof, are intended to include not only the exact amount or value that they qualify, but also some slight deviations therefrom, which may be due to manufacturing tolerances, measurement error, wear and tear, stresses exerted on various parts, and combinations thereof, for example.

[0016] Finally, as used herein any reference to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.

[0017] Referring now to drawings, and more particularly to FIG. 1 , a pipe conveyor apparatus 10 constructed in accordance with the inventive concepts disclosed herein is illustrated. The pipe conveyor apparatus 10 is adapted to be positioned adjacent a pipe storage rack 12 for facilitating the transport of a joints of pipe 4 between the pipe storage rack 12 and a pipe storage rack 15 positioned on a rig floor 16 of a rig 17 wherein the rig floor 16 is elevated a distance above the pipe storage rack 12.

[0018] Referring now to FIGS. 1-5, the pipe conveyor apparatus 10 includes a pair of boom assemblies 18 and a drive assembly 20. As best shown in FIG. 1 , the boom assemblies 18 are positionab!e to support at least two joints of pipe 14 in a spaced apart and substantially horizontal position with the ends of the joints of pipe 14 positioned in a non-contact relationship with respect to the boom assemblies 18. Each of the boom assemblies 18 includes a base frame 22, a boom support frame 24 positioned on the base frame 22, and a boom 26 pivotally connected to the boom support frame 24 so that the angular relationship of the boom 26 relative to the base frame 22 is adjustable.

[0019] The base frame 22 is configured to support the boom support frame 24 and to facilitate movement of the boom assembly 18 to a desired location at the well site. The base frame 22 is shown to be constructed of a plurality of beam members arranged in a substantially rectangular configuration. However, any suitable structure can be employed as the base frame 22 so long as the structure permits the boom assemblies 18 to be easily moved to the desired location at the well site. Each of the base frames 22 may be provided with a boom support cradle 28 at one end thereof to support the boom 26 for transport.

[0020] The boom support frame 24 includes a horizontal base portion 30 and a vertical portion 32. The base portion 30 is generally rectangular in shape and is sized to extend across the base frame 22 so as to provide a platform for the vertical portion 32. The base portion 30 is slidable over at least a portion of the base frame 22 in a to-and-fro direction. The base portion 30 may be connected to the base frame 22 with any suitable structure, such as a plurality of guides 34 (best shown in FIG. 3) extending from opposing sides of the base portion 30 and engaging with flanges of the base frame 22 so as to permit the boom support frame 26 to slide relative to the base frame 22. The base portion 30 is further connected to the base frame 22 with a plurality of cylinders 36 which serve to adjust the horizontal position of the boom support frame 24, and thus the boom 26, relative to the base frame 22. The cylinders 36 have one portion attached to the base portion 30 of the boom support frame 24 and another portion in the form of a reciprocating rod 38 attached to the base frame 22. The cylinders 36 can be any suitable cylinders known in the art, such as double-acting hydraulic cylinders.

[0021] The vertical portion 32 of the boom support frame 24 extends upwardly from the base portion 30 to support the boom 26 an elevated level above the base frame 30. The vertical portion 32 includes a stationary assembly 40 and a boom connector assembly 42. The boom connector assembly 42 is adapted to be connected to the boom 26. In addition, the boom connector assembly 42 is pivotal!y connected to an upper end of the stationary assembly 40 so that the angular relationship of the boom 26 relative to the base frame 22 is adjustable. The boom support frame 24 further includes a cylinder 44 interposed between the base portion 30 and the boom connector assembly 42 to effect angular movement of the boom connector assembly 42, and thus the boom 26, relative to the base portion 30.

[0022] Each of the booms 26 is an elongated member with a proximal end 50 and a distal end 52. The boom 26 has a length sufficient to extend from the pipe storage rack 12 to the pipe storage rack 15 positioned on the rig floor 16. Each of the booms 26 is provided with a first sprocket 54 rotatably connected to the proximal end 50 of the boom 26 and a second sprocket 56 rotatably connected to the distal end 52 of the boom 26. A chain 58 is extended over the first sprocket 54 and the second sprocket 56.

[0023] A plurality of pipe support lugs 60 are connected to the chain 58 so that the pipe support lugs 60 are movable along the length of the boom 26 between the proximal end 50 and the distal end 52 upon actuation of the chain 58. The pipe support lugs 60 extend from the chain 58 and the boom 26 to engage the underside of a joint of pipe 14 and cooperate with an upper side of the boom 26 to support the joint of pipe 14. The pipe support lugs 60 are shown (FIG. 4) to have a generally rectangular configuration. In one embodiment, the pipe support lugs 60 have a length substantially equal to the outer diameter of the joint of pipe 14 to be conveyed such that corresponding pipe support lugs 60 from the boom assemblies 18 grab only a single joint of pipe 14 when the joints of pipe 14 are being automatically fed from the pipe rack 12 to the pipe conveyor apparatus 10 by gravity or some other manner. It will be appreciated, however, that the pipe support lugs 60 may be formed in a variety of configurations and sizes. In addition, the number of pipe supporting lugs 60 connected may be varied. In one embodiment, each of the booms 26 has at least three pipe supporting lugs 60 extending from each side of the boom 26 at any one time so as to be able to support at least three joints of pipe in a spaced relationship to one another at any one time. The chain 58 may be a continuous loop such that the pipe support lugs 60 are movable in a looping fashion along one side of the boom 26, around the distal end 52, along an opposing side of the boom 26, and around the proximal end 50.

[0024] To facilitate transport of the joints of pipe 14 along the boom 26, the booms 26 may be provided with a low friction guide rails 62 (FIG. 52) along the upper surface of the boom 26. The rails 62 may be spaced to receive the chain 58 there between.

[0025] With reference to FIGS. 2-4, the drive assembly 20 is operably connected to the pipe support lugs 60 in such a way that the pipe support lugs 60 of the boom assemblies 18 are moved in unison so as to move the joints of pipe between the proximal end 50 and the distal end 52 of the booms 26. The drive assembly 20 generally includes a motor 70, a first drive shaft 72 operably connected to the motor 70, a second drive shaft 74 having one end interconnected to the first drive shaft 72 and another end connected to the first sprocket 54 of one of the booms 26, and a third drive shaft 76 having one end interconnected to the first drive shaft 72 and another end connected to the first sprocket 54 of the other boom 26. The motor 70 can be any suitable hydraulic motor. In one embodiment, the motor 70 is linked to the first drive shaft 72 by a chain 78 extending between a drive sprocket 80 of the motor 70 and a sprocket 82 of the first drive shaft 72. Each end of the first drive shaft 72 may be provided with sprockets 84 which are in turn linked via a chain 86 to sprockets 88.

[0026] The motor 70, the first drive shaft 72, and the sprockets 84 and 88 are supported by a support beam 90. The support beam 90 is sized to extend from one of the base frames 30 to the other base frame 30. To facilitate transport of the pipe conveyor apparatus 10, the support beam 90 is provided as a separate structure from the boom assemblies 18. In one version, the support beam 90 is supported on the base frames 22 with a plurality of cradles 92 whereby the drive assembly 20 may be removed from the base frames 22 by lifting the support beam 90 from the cradles 92. With the support beam 90 removed from the cradles 92, the boom assemblies 18 are in a non-connected relationship with one another thereby facilitate transport of each.

[0027] The second drive shaft 74 and the third drive shaft 76 are interposed between the sprockets 88 of the drive assembly 20 and the first sprocket 54 of the boom booms 26. To accommodate the adjustability of the booms 26, the second drive shaft 74 and the third drive shaft 76 are self-adjusting with respect their length and are universally coupled to the sprockets 88 and the first sprockets 54.

[0028] The motor 72 and the cylinders may be powered with any suitable hydraulic power system (not shown), such as the hydraulic power system used to operate various components of the rig. The hydraulic power system may include a control panel (also not shown) which has corresponding control valves for actuating the motor 72 and each of the cylinders. The control panel may communicate with the motor 79 and the cylinders wirelessly, or otherwise be remote, whereby an operator can be positioned at a safe location from the pipe conveyor apparatus 10. The construction and operation of hydraulic power systems are well known in the art. Thus, no further description of the various types of hydraulic power systems, their components or their operation is believed necessary to enable one skilled in the art to understand the pipe conveyor apparatus 10 disclosed herein

[0029] In use, the pipe conveyor apparatus 10 can be transported to the work site by any suitable means, such as a low-bed trailer or truck (not shown). With the pipe conveyor apparatus 10 transported to the work site, the boom assemblies 18 are unloaded and positioned in a spaced apart parallel relationship to one another adjacent the rig 17. The drive assembly 20 may than be positioned on the base frames 30 and the second and third drive shafts 74 and 76 connected to the first drive shaft 72 and the sprockets 54, respectively. The pipe storage racks 12 are positioned in a parallel relationship to booms 26 so that the joints of pipe 14 on the pipe storage racks 12 are positioned in a perpendicular relationship to the booms 26. The height and angle of the booms 26 of the pipe conveyor apparatus 10 may then be adjusted, if necessary, to position the proximal end 50 of the booms 26 at a height level with or slightly below the height of the pipe storage rack 12 to permit the joints of pipe 14 on the pipe storage rack 12 to be easily transported onto the booms 26 by a workman, or by gravity, and in turn captured by the pipe support lugs 60 and to position the distal end 52 of the booms 26 at a height level with or slightly above the height of the pipe storage rack 15 to permit the joints of pipe 14 to be easily deposited onto the pipe storage rack 15 from the booms 26.

[0030] It will be appreciated that if the pipe conveyor apparatus 10 is being utilized to transport joints of pipe 14 from the rig floor 16 to the pipe storage rack 12, it will be desirable to position the proximal end 50 of the booms 26 at a height level with or slightly above the height of the pipe storage rack 12 to permit the joints of pipe 14 on the booms 26 to be easily transported onto the pipe storage rack 12 and the distal end 52 at a height level with or slightly below the height of the pipe storage rack 15.

[0031] To transport a joint of pipe 14 from the pipe storage rack 12 to the rig floor 16, the motor 70 is actuated to cause the pipe support lugs 60 to move in unison along the booms 26. An operator then rolls the joint of pipe 14 (as shown in FIG. 1) onto the booms 26 so that the pipe support lugs 60 capture the joint of pipe 14. The motion of the pipe support lugs 60 then carry the joint of pipe 14 along the booms 26 to the distal end 52 where the joint of pipe 14 is deposited onto the pipe storage rack 15 provided on the rig floor 16. Because of the loop configuration of the chain 58, the pipe support lugs 60 continue capturing and transporting joints of pipe 14 so long as joints of pipe continue to be positioned onto the booms 26.

[0032] When the pipe conveyor apparatus 10 is employed to remove joints of pipe 14 from the rig floor 16, the motor 70 is actuated to cause the pipe support lugs 60 to travel in an opposing direction to that used to move the joints of pipe 14 from the pipe rack 12 to the rig floor 16. The joints of pipe 14 are then positioned on the distal end 52 of the booms 26 and the pipe support lugs 60 support the joints of pipe 14 and carrying them down the booms 26 to the proximal end 50 of the booms 26 where the joints of pipe 14 are deposited on the pipe storage racks 12.

[0033] From the above description, it is clear that the inventive concepts disclosed herein are well adapted to carry out the objects and to attain the advantages mentioned herein as well as those inherent in the inventive concepts disclosed herein. While exemplary embodiments of the inventive concepts disclosed herein have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the scope of the inventive concepts disclosed and as defined in the appended claims.